Fire protection containers incorporating novel low free water insulation materials

Abstract

The present invention contemplates water-bearing silicate materials achieved by modifying the basic method of essentially reacting water glass with calcium chloride to bind the free water into solid form without adversely affecting the basic chemical and physical structure of the original product. The material is then dried by using a wicking agent, such as cellulose sponge, adding an anhydrous salt to the material to form a crystalline hydrate, or adding calcium oxide or calcium hydroxide to the material to form a microstructure that physically retains the water. The material is then incorporated into a fire protection contained in which the material forms the outermost wall of the container, a light-weight porous material such as urethane foam and intermediate layer, and a phase change material with a melting point of about 70 degrees F. to 125 degrees F. forms the innermost wall.

1. A fire protective container, comprising:
 a. an outer wall consisting essentially of:
 i. water glass composed of a sodium silicate solution that is about 40% solids, 60% water, and having a SiO2:Na2O ratio in the range of about 2:1 to 4:1; 
 ii. calcium chloride; and 
 iii. an additive chosen from the group of calcium oxide or calcium hydroxide. 
 
 
     
     
       2. The fire protective container of  claim 1 , further comprising:
 a. an intermediate wall; and 
 b. an inner wall composed of a phase change material. 
 
     
     
       3. The fire protective container of  claim 2 , wherein said outer wall is about 1 to 2 inches thick, said intermediate wall is about 0.5 to 2 inches thick, and said inner wall is about 0.25 to 1 inch thick. 
     
     
       4. The fire protective container of  claim 3 , wherein said intermediate wall is composed of urethane. 
     
     
       5. The fire protective container of  claim 3 , wherein said intermediate wall is composed of polystyrene foam. 
     
     
       6. The fire protection container of  claim 1 , wherein said outer wall further consists essentially of:
 a. spray dried sodium silicate; and 
 b. propylene glycol. 
 
     
     
       7. The fire protection container of  claim 2 , wherein said outer wall consists essentially of:
 a. 56 parts by weight of said water glass; 
 b. 0 to 12 parts by weight of said spray dried sodium silicate; 
 c. 4 to 10 parts by weight of said additive; 
 d. 2 to 10 parts by weight of said calcium chloride; and 
 e. 0 to 3 parts by weight of said propylene glycol. 
 
     
     
       8. The fire protection container of  claim 1 , wherein said outer wall further consists essentially of anhydrous dibasic sodium phosphate. 
     
     
       9. The fire protection container of  claim 8 , wherein said anhydrous dibasic sodium phosphate is added in 4 to 12 parts by weight. 
     
     
       10. A fire protection container, comprising:
 a. an outer wall consisting essentially of:
 i. water glass composed of a sodium silicate solution that is about 40% solids, 60% water, and having a SiO2:Na2O ratio in the range of about 2:1 to 4:1; 
 ii. calcium chloride; 
 iii. propylene glycol. 
 
 
     
     
       11. The fire protection container, comprising:
 a. an outer wall consisting of:
 i. water glass composed of a sodium silicate solution that is about 40% solids, 60% water, and having a SiO2:Na2O ratio in the range of about 2:1 to 4:1; 
 ii. calcium chloride; 
 iii. water soluble oil; and 
 iv. calcium oxide. 
 
 
     
     
       12. The fire protection container of  claim 11 , wherein said outer wall consists essentially of:
 a. 20 parts by weight of said water glass; 
 b. 1 part by weight of said water soluble oil; 
 c. 2 to 3 parts by weight of said calcium oxide; and 
 d. 2.4 to 3.2 parts by weight of said calcium chloride.